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By Murray Wood, Michael Schaffer, Makat Katom

"An expert system applied to the control of mineral process unit operations is, by its nature, the site best operating practice, having been designed by the local experts in conjunction with consulting metallurgists. The “common sense” layer in a MET (MinnovEX Expert Technology) solution determines an appropriate action for the current operating conditions through a developed heuristic model of the process (expert system). The magnitude of the setpoint change that is made is proportional to the confidence that the system has in its interpretation of the current conditions (fuzzy logic). The solution is always striving to take the process to a constraint and thereby optimise the operation. An accepted limitation of the solution is that the only way the system can determine if a constraint has been reached is to exceed it and then withdraw – essentially “experimenting” with the process. By leveraging a model, which can accurately ""simulate"" the process, this restriction can be circumvented by pre-testing the set point change through a ""what if"" analysis and then modifying the solution as appropriate.At Ok Tedi, the introduction in 1999 of a MET expert system for SAG milling resulted in significant improvement in circuit throughput. Yet, with the additional inclusion of an accurate model of the process there was still more that could be achieved. Hence, in 2002 a MET Neural Network model was developed and deployed to enhance the existing expert system solution. The principal objective of this model was predicting the effect that changes in SAG tonnage and density would have on the power draw of the mill - essentially a power predictor. The results have seen a decrease in process variance with an associated increase in average circuit performance.This paper describes the methodology by which the Neural Network model was implemented, the considerations and limitations when applying this technology and ultimately the results that were achieved."

Jan 1, 2003

Choosing the right valve for corrosive, abrasive slurry applications requires exacting analysis and a comprehensive understanding of the complete slurry process. Within the realm of flow control in abrasive and corrosive slurry applications, there is no room for a one-size-fits-all approach. To ensure minimal maintenance, maximum uptime and the lowest overall cost of ownership, the slurry processing toolbox must contain countless alloy and elastomeric pairings ? each carefully targeted to the particular process medium and conditions. This materials selection process is best tackled by turning to expert slurry application engineers and valve product managers who work closely with customers to specify the optimal valve for the given parameters. ?When plant operators and design engineers apply conventional valves in abrasive applications or use metal seated valves or simply apply the wrong valve for a particular flow control situation, it typically leads to rapid valve failure, the potential for hazardous leakage, unexpected shutdowns and costly downtime,? said Cal Cobb, valve products manager for Weir Minerals North America, manufacturer of Isogate slurry valves for service in mining, minerals processing and metallurgical environments.

Jan 1, 2011

By Muhammad Yamani, Marsell Riviera, Herry Saputra, Rizky Amin

Drill and Blast processes in hot and reactive ground conditions are a severe challenge in mining, especially in the blasting process. Our main objective is safety issues without compromising the blasting outcome. Safety concerns include unexpected detonation, product damage, and misfire. However, apart from the issue of blasting safety, it is also crucial to maintain good results such as fragmentation, loader productivity, and ore dilution control. Therefore, we use a different product selection method to produce a safe and efficient blast. Pit Araren is one of the pits of the Tokatindung Gold Mine Project in North Sulawesi Province, Indonesia, classified as hot and reactive ground conditions that range from elevation of 25mRL temperature could reach to 98⁰C (208,4⁰F) based on actual measurement. The previous practice for blast holes with temperatures above 70⁰C (158⁰F) loaded with the primer that was specifically designed for hot and reactive ground conditions consisting of detonating cord and packages emulsion that specifically formulated to inhibit exothermic reaction then tied in with a combination of non-electric surface delay detonator and detonating cord initiator (short length non-electric surface delay detonator housed in plastic connector).

Feb 6, 2023

By Milance Mitovski, Milorad Cirkovic, Vlastimir Trujic, Dragana Živkovic

"In this article, it is analysed the possibilitis and the effects utility waste energy of process sulfuric acid production in the existing technical-technological conditions. The utility second process energy, reduction the fuels consumption, reduction environment pollution and its effects are shown, too. High heat quantity is produced as the result of exothermal reactions in the production process of sulfuric acid in Bor. A part of this heat is sufficient for the process development, and significant part of this heat presents low-temperature heat energy that is irretrievable lost. Investigations were carried out based on production of 485 t of monohydrate/day of sulfuric acid. By recovery of this heat quantity for heating purposes, about 20.000 – 25.000 t of coal/year would be saved, what would significantly improve the power efficiency of the smelter copper production. IntroductionTechnological process of copper production in RTB BOR (Serbia) produces a significant quantities of high temperature secondary (waste) heat energy that is uncontrolled “lost” in the vicinity. Secondary heat energy is produced in pyrometallurgical copper production in quantity of 1,621 kWth/kg of dry concentrate or existing heat (that presents a difference of heat at furnace outlet and heat at temperature over temperature of dew point of sulphuric acid gases) in quantity of 1,315 kWth/kg of dry concentrate. For designed capacity of Copper Smelter in Bor, the existing heat power of secondary energy is 92,111 MWt, what is an equivalent to the power of steam-turbo plant where the Rankine-Clausius heating cycle is done, and that is 28,334 MWe."

Jan 1, 2008

Virtually all mineable Appalachian coal seams exist in a multi-seam environment. This makes it inevitable that most seams will eventually experience interaction induced ground control and mining problems. Indeed, it has been estimated that every working face will experience interaction effects from previous or current workings at least once during its lifetime (1), and that these problems are considerably exaggerated when seams are in close proximity -- a distance of less than 110 feet. The continued increase in multi-seam problems has resulted in considerable research activities over many years (2,3,4,1). Theoretical analysis, numerical and physical model studies, statistical and empirical analysis of numerous interaction related field data have been applied to multi-seam mining situations and have identified many useful trends and design criteria (4,5,6,7). To fully utilize research results and transfer multi-seam mining technology to field engineers, a design model -- USEAM was constructed (8). This model, designed for close seam under-mining situations, was computerized to facilitate utilization. In the current research, a new computer program "MSEAM" was developed to produce a model for both under- and overmining close seam situations. It is hoped that both of these software packages will aid field engineers in using important interactive design criteria to gain a better understanding of interaction mechanisms. Through advance planning with these programs, detrimental interaction may be avoided and minimized, and occasionally a design can be selected which will allow interaction effects to be utilized to the benefit of mining operations.

Jan 1, 1987

By Wm. R. Webster

THIS is a contribution for the proposed new discussion on the physics of steel. The former discussion on the subject started with the consideration of five papers presented at the Chicago meeting in 1893, and continued for several years. The Suggested Lines of Discussion, prepared by Doctor Howe, covered a wide field and added greatly to the success of the work. Naturally, the first step in a new discussion will be to remodel and bring up to date the old Suggested Lines of Discussion so as to embody all the important advances in the metallurgy of steel that have a bearing on the physics of steel and keep the papers and discussions within the field of work undertaken. This paper will be devoted to the practical application, in rolling steel, of the effects of carbon, phosphorus, and manganese on its tensile strength, with some suggestions on further research work. Dr. J. E. Stead, in his paper Influence of Some Elements on the Mechanical Properties of Steel,1 gave a complete review of all that had been done during the past thirty years. He gave full credit to all investigators who worked on these lines, also their results, with his views on same, and in many cases his own results. All of this data and much new valuable information were put in convenient shape for reference and study. To do this required a great deal of work, which is fully appreciated by the steel manufacturers and investigators. The variations in the values given by the different investigators for the increase of the tensile strength of steel for each 0.01 per cent. of carbon, phosphorus, and manganese were largely due to the steels they worked on, the large or small variations in the amount of the elements present, and the omission to take into consideration all the factors, from the blast furnace through to finished rolled material, that affect the character of the steel. For instance, a poorly made dirty steel requires considerably more carbon to give the same ultimate strength than a well-made clean steel with the same phosphorus and manganese content.

Jan 3, 1921

By Waldemar Gooskov

IN his well-known work,1 published in 1867, P. Ritter von Rittinger gives the following formula for the velocity of a particle settling in still water: v=C/D(a -1) and for average grains he assigns to the constant C a value of 2.44. As is well known, the value of C depends on the shape of the grains resulting from crushing, and it is obvious that values obtained for coal particles will not only be very different from those for ore particles but will even be characteristic of coal from a certain seam. The only way of finding an accurate value of C, applicable to conditions in Russia, where all coal-washing plants are built on German principles, is to conduct a series of tests of which the results will determine what value of C is to be used. In the investigation outlined in this paper the theories of Prof. Robert H. Richards2 were taken as the basis of the tests; the slimes were removed from the charges to eliminate the trouble of handling them; and to obtain accurate results free from errors inevitably resulting from human observation, photographic apparatus was used and a series of pictures taken which form the basis for constructing a suitable diagram of velocity vs. time.3

Jan 1, 1928

By Paul C. Miclea

In case of a major fire in a tunnel between stations or ventilation shafts, if the buoyancy effect of the hot gasses is stronger than the airflow induced by the fans, the risk of backlayering could restrict the safe evacuation of people. Obstructions in the tunnel and alternate airflow paths can further reduce the air velocities past the fire. Currently there are two computer programs available to address the issue of underground fires: o "Subway Environment Simulation" (SES), Version 3.0, developed by Associated Engineers, a Joint Venture of Parsons Brinckerhoff Quade & Douglas, Inc., De Leuw Cather & Co., and Kaiser Engineers, Inc. for the U.S. Department of Transportation o "MFIRE", Version 1.26, developed at Michigan Technological University for the U.S. Department of the Interior, Bureau of Mines. As implied by its name, the SES program was developed specifically for the analysis of subway ventilation systems. It can be used to analyze the heat released into, and removed from, a subway or vehicular tunnel and to determine the effect of ventilation elements on airflows throughout the network of stations or other merging tunnels. It has a special feature allowing the user to predict the effects of a fire at any location within the subway system. Version 3.0 of the SES program is designed to be used with a "critical velocity" calculation in order to determine whether or not tunnel airflows can be controlled during a train fire emergency. The original version of the program was written in FORTRAN for mainframe computers, such as the IBM 4381. Recently ICF Kaiser Engineers has compiled a version of the SES program for PC use. The MFIRE program simulates the interdependence between a mine ventilation system, with its pertinent fans and structures, and changes in ambient conditions or a source of heat, such as a fire. It also accounts for natural ventilation. The program is written in FORTRAN 77 and compiled for 8086/8088 based microprocessors, allowing it to be run on an IBM PC or compatible computer with a 2.0 or a later version of DOS, 256K random access memory (RAM), and a text editor. This paper reports the comparative results of an application of both programs for the same network in a recent study.

Jan 1, 1991

By J. L. Fuentes

The so called 'SISCOM' is a General Purpose, microprocessor-based Monitoring and Control System, developed by AITEMIN to meet the requirements of Spanish Mining Industry in - the field of automation and data -transmission. Typical applications -are automatic control of pumps, compressors, fans and conveyors, as well as environmental monitoring and production monitoring. In relation with the last, the - System has been succesfully installed in a full section roadheader and in a mechanised steep coal face. In both cases, the main objective is to get information about running times, down times and causes, -and monitoring of other important parameters such as ventilation, methane content, power consumption..etc. Measurements concerning the face behaviour from a geomechanical point of view are also monitored. These are different pressures and stresses. All data is transmitted to the - surface and on-line analysed by a -desk-top microcomputer. The paper shows the system structure and the requirements that have - been considered on its design. Attention is given to the mechanical data acquisition problem, involving special development of some transducers. The information provided by the surface microcomputer is shown and its utility discussed.

Jan 1, 1986

By B. W. Cavender

"World-class manufacturing" (WCM) techniques can be applied in milling operations to substantially improve productivity and reduce costs. Through the use of "just-in-time" and "total quality control" practices, WCM methods establish an environment for continual and rapid improvement in all aspects of production operations, with particular gains in product quality, costs, flexibility, employee involvement, and responsiveness to customers. This paper examines WCM techniques that can be utilized specifically in the mill, and their influence on plant configuration, organization, and scheduling practices; equipment selection and maintenance methods; training; the role of supporting staff; and methods of data collection and analysis.

Jan 1, 1993

By Ruilin Lang

This paper presents an application of 3-D plots and non-linear regressions to define a sitespecific form of the charge weight scaled distance. The PPV (PPA) of single hole blasts is normally considered as a function of two independent variables - the charge weight and the distance. It is of great importance to obtain the relationship of the function accurately for a concerned site in terms of blast vibration analysis and modeling. However, in pre-computer time it was difficult to plot 3-D graphs. Consequently, a charge weight scaled distance was used to plot the PPV (or PPA) against the scaled distance as 2-D graphs. Blast vibration investigators use several forms of the charge weight scaled distances to plot data. We can exemplify them with the cube root of charge weight scaled distance, the square root of charge weight scaled distance, and other forms (Hossaini and Sen, 2004). Each of these scaled distances assumes relative contributions of the charge weight and the distance to the vibration attenuation. For example, the charge weight is assumed to have a less contribution to vibration in the cube root scaled distance than it is assumed in the square-root scaled distance. In reality, for different sites the relative contribution of the charge weight and the distance may be different and site-specific. This may explain that in some cases, the blast vibration data plots using these charge weight scaled distances are scattered. This could be largely due to the fact that the definition of the form of the charge weight scaled distance is not adequate for the particular site condition.

Jan 1, 2006

By F. A. Molloy

As a result of feasibility studies made in 1975 a 3-0 seismic reflection survey was shot over part of the Veendam salt pillow during 1978-1979. The Zechstein salt pillow, located in the northeast of the Netherlands near the town of veendam, occurs at a depth of 1400 m and contains three carnallite rich horizons over an interval of 300 m below top salt. MgCl2 brines are produced from these layers as feedstock for a magnesia plant, which starts up in 1981. Prior to the acquisition of the seismic data four wells had been drilled. The thickness of the carnallitite layers encountered in these wells varied between 50 and 125 meters. In view of these variations it was necessary to obtain a reliable isopach of the different layers. The 3-0 seismic survey covered an area of ± 4x4 km with a sampling interval of 20 m in all directions. The data was recorded it an area array using a 120 channel instrument. Final presentation of the data was in the form of 3-0 migrated acoustic impedance cross sections. The quality and resolution of the seismic data allowed reliable structural and isopach mans to be made. It was shown that the carnallitite layers are continuous over the area surveyed, whilst local thickening is "fault" related. Having this information brine production locations could be choosen in the thicker parts, allowing maximisation of production potential whilst avoiding faults and fulfilling mining regulations. A subsequent benefit of this approach is the possibility of using the seismic data to predict ore grade. Using the available wells as calibration points the acoustic impedance response of the seismic at the well was matched to the ore grade found. From these points a synthetic section was made with varying ore grades. Pre¬liminary results are encouraging and the liability of this predictive tool will be evaluated in the light of future drilling.

Jan 1, 1981

By M. H. B. Nasseri

Barre granite?s samples have been tested for fracture toughness under mode I along two different directions with respect to microstructural fabrics were investigated. 3D objects counter algorithm technique is applied on micro CT images to identify physical properties such as crack induced porosity, crack density, generated total surface area and contribution of individual mineral grains within the damaged zone.The result obtained justifies very well the fracture toughness anisotropy in Barre granite, and explains the difference in the structure of the damage zone evolving as a result of test crack interacting with pre-existing microstructural fabrics. The present study has potential application in the fields of rock mass stability, oil reservoir stimulation, rock fragmentation and damage in blasting and emplacement of dykes.

May 1, 2009

By Purvis A. H, Greenwood-Smith R, Sowerby B. D

A nuclear technique for the determination of copper and nickel in bulk samples and drill core has been developed at Lucas Heights andfield-tested at Mount Isa. The technique, which is highly specific to the element being measured, utilises the gamma-ray resonance scallering process.A bulk mineral analyser was installed in mid-1976 for the routine assay of copper in bulk samples and drill cores, and remained in operation until late 1981. The operation of the analyser over this five-year period is reviewed with particular emphasis on reliability, accuracy and principal usage.The main application of this analyser was in stope planning and design whereby several thousand drill-core and Wall-chip samples were analysed. It was also used as an aid to underground grade control of stopes where ore dilution by supporting barren backfill was a problem.

Jan 1, 1984

By L. Barry Phelps

The application of an open-pit Materials Handling Simulator (OPMHS) to analyze mine planning and scheduling problems in large surface mines is discussed. The mine chosen for this application employed a large stripping dragline working in tandem with a shovel-truck haulback system for removing overburden. Large bottom-dump trucks were employed behind a coal loading shovel to transport the exposed coal out of the pit. Specifically, the current operations and the recommendations for short term and long term improvements were simulated on OPMHS. The effects of changing the operating parameters of the equipment on the total system were evaluated. Several alternatives were also studied for the best use of the existing equipment if the current operating parameters could not be improved upon. The results of the application are discussed.

Jan 1, 1978

By C. L. Lewis

"The development of computer process control at the Lake Dufault concentrator is reviewed and the on-stream X-ray analysis -computer system is described briefly. Some applications of the computer in metallurgical process control are described.The computer sequences slurry sample streams to the analyzer and translates the analytical results from voltage signals to elemental percentages. The required flotation reagent flow rates are calculated from analyses and mill-feed tonnage rates and the reagent feeders are set automatically to provide such flow rates. X-ray calibration time has been reduced from about 45 minutes to 15 minutes by the use of a computer program. Metallurgical and operating personnel have acquired the ability to program the computer and have extended the system capability to allow the calculation of recoveries, averaging of mill data, application of ore specific gravity in grinding control, control of oxidized ore flotation and the development of an economic recovery program."

Jan 1, 1971

By D. H. Pulling

Statistics for copper consumption from various sources show that the importance of production from secondary sources is increasing. This is of particular significance in countries such as the U.K ., which are totally dependent on secondary material for the supply of home-produced copper . A brief survey of the U.K . industry has shown that, in the past, relatively high profit margins have not encouraged high cap ital investment and development of more sophisticated operating techniques, but set against a background of rapidly escalating operating and energy costs , together with an ever-increasing demand for copper , it is anticipated that the industry will see great changes in the near future. With this in mind, an experimental furnace for continuous smelting of copper-bearing scrap has been developed at the University of Birmingham. This furnace has been designed to combine the conventional operations of blast furnace or reverberatory smelting, usually followed by converting, in one unit, and incorporates many of the features of the WORGRA and Noranda processes for continuous primary smelting . It consists of a long, sloping channel, constructed of chrome-magnesite refractory, which: is churned near the top. Smelting is effected lower down the channel, where iron, etc., in the scrap is oxidized and slagged off with silica flux. Provision is made for oil injection to increase oxidation rates. Metal can flow from the bottom of the channel, and slag from the top, so that a counter-current flow is achieved. The approximate molten capacity is 25 kg. Various scrap charges, both synthetically made and as supplied from various industrial smelters, have been successfully smelted. Metal of 83 -95 % Cu has been produced, depending on the original charge composition and the degree of air injection, although air injection was also found to considerably increase the copper loss to slag. Recoveries of other valuable non-ferrous metals in the charge were good.

Jan 1, 1977

By R. W. Zeindler, D. A. Fawcett

"A summary is presented of the report completed by the Coal Mining Research Centre in 1980. This report was of a cross-pit conveyor system applied as an auxiliary mining complement to the major stripping unit, a dragline. The purpose of the CMRC report was to evaluate selective mining and replacement of the upper horizons of the strata as an aid in reclamation. These strata were the topsoil, subsoil and glacial till.Past utilization of cross-pit conveyor systems and related engineering studies were assessed. The parameters of the study were based on the mining and geological conditions of the Alberta prairie coal mines. The principal excavator for stripping was a dragline. Excavation of the upper horizons was done by a bucket-wheel excavator discharging onto the crosspit conveyor. Alternative equipment applications were economically compared. Four cases or geological sections were evaluated in detail. The economics of the alternative mining systems for each of the cases were determined. In all instances, the most economical solution was a tandem system utilizing a dragline with a bucket-wheel excavator/ cross-pit conveyor system."

Jan 1, 1981

By Radenkovic C, Ivkovic S, Minic I

The model, already tested and applied, enables a highly efficaceous solution of the problem of issuing instructions for interested services on the basis of known contents of in- dividual stages of mine mechanization repair and known time intervals between repairs for specific machines and total mechanization. Application of the model provides work orders for all types of repairs for specific machines or systems, and orders for the commercial department regarding spare parts Supply.

Jan 1, 1977

By Dr. David R. Hargis

Finite-difference digital computer models can be used to evaluate the effects of proposed mine dewatering and depressuring operations on ground-water aquifer systems. The effects of proposed dewatering and depressuring operations can be simulated for both underground and open-pit mining in confined and unconfined aquifer systems. Design of dewatering and depressuring well arrays to accommodate proposed mining operations in a variety of hydrogeologic settings can be accomplished through judicious application of well-documented and tested computer programs that are widely available from government agencies and universities. The speed and flexibility of the computer models can provide an economical means for comparison of alternative mining plans, and can be used to determine the optimum mine plan with respect to dewatering requirements.

Jan 1, 1980